Study on the Effect of Energy-Input on the Joint Mechanical Properties of Rotary Friction-Welding

Abstract

The objective of the present study is to investigate the effect of energy-input on the mechanical properties of a 304 stainless-steel joint welded by continuous-drive rotary friction-welding (RFW). RFW experiments were conducted over a wide range of welding parameters (welding pressure: 25–200 MPa, rotation speed: 500–2300 rpm, welding time: 4–20 s, and forging pressure: 100–200 MPa). The results show that the energy-input has a significant effect on the tensile strength of RFW joints. With the increase of energy-input, the tensile strength rapidly increases until reaching the maximum value and then slightly decreases. An empirical model for energy-input was established based on RFW experiments that cover a wide range of welding parameters. The accuracy of the model was verified by extra RFW experiments. In addition, the model for optimal energy-input of different forging pressures was obtained. To verify the accuracy of the model, the optimal energy-input of a 170 MPa forging pressure was calculated. Three RFW experiments in which energy-input was equal to the calculated value were made. The joints’ tensile strength coefficients were 90%, 93%, and 96% respectively, which proved that the model is accurate.

Influence of the rotary friction welding parameters on the microhardness and joint strength of Ti6Al4V alloys

“…Generally, the heat supplied during the welding process is a technological factor that determines the success of friction welding for Ti4Al6V. 13 However, the most important parameter that affects the weld quality is the axial pressure. This factor strongly affects the tensile strength and microhardness of the welded joint.…”

“…Therefore, the change in these parameters affects the quality of the welded joint. Many researchers have investigated the effect of friction welding parameters on the welded joint quality of stainless steel, 13 aluminium and copper, 14,15 for example, to find the optimal friction welding parameters. However, the rotating friction welding process is complex and nonlinear, and it is strongly affected by the mechanical and thermal properties of welding materials.…”

Effects of joint heat distribution on material flow and microstructure in continuous drive friction welding of 45 # steel

“…Three regions were observed, consisting of the weld zone (WZ), partially deformed zone (PDZ) and base metal (BM). 14 The radial division of the joint area are shown in Figure 22. Three regions were observed, including the edge zone、the 0.5 R zone and R zone.…”

“…It was not necessary to measure the applied force and identify the interaction between the damping and fluid-structure, but only need to use limited measurement points to predict strain response. A model was established for the energy input as a function of the welding parameters by Wang et al 14 The maximum temperature exhibited no obvious variation regularity with changes in the energy input. The length of the thermal cycle exhibited a positive correlation with the energy input.…”

Optimization of Friction Welding Process Parameters for 42Cr9Si2 Hollow Head and Sodium Filled Engine Valve and Valve Performance Evaluation

“…There are five main controllable variables in the two-stage IFW: flywheel mass (I, moment of inertia), weld speed (S w ), weld pressure (P w ), upset speed (S u ), and upset pressure (P u ). As suggested by Wang et al [21], in practical applications of rotary friction welding, it should be adjust several welding para meters simultaneously based on the actual condition, such as the welding material properties and the welding machine’s condition. At first, the IFW parameters were gathered empirically, which is also referred to as a “trial and error” method.…”